Construction blocks

ABSTRACT

An interlocking construction block system comprising a family of blocks that interlock along three axes, including a left/right axis, a front/back axis, and an up/down axis. The family of blocks are self-aligning and do not require skilled labor or mortar to create a structure of any length, width, height, or shape. Each block comprises a specific geometry that allows all blocks in the family to interlock in a woven pattern that not only locks the blocks in place but also allows even distribution of structural weights and stresses. The disclosed blocks can be manufactured in different sizes to conform to any building code requirement and to create wall lengths to a one-inch measurement. The blocks may comprise channel openings to allow for plumbing, electrical, and structural reinforcements in the structure and may each be reinforced with an internal mesh cage.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.15/467,324, filed Mar. 23, 2017 which is incorporated herein byreference in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to masonry units, and moreparticularly, to improved construction blocks that interlock in threedirections to create any length or width of wall structure without theneed for a bonding agent such as mortar during assembly.

BACKGROUND

Traditional concrete construction blocks are often rectangular shapedblocks that require mortar and a skilled mason to assemble the blocksinto a desired structure. Improper placement of the blocks and/orinsufficient or excessive mortar can compromise the integrity and safetyof the structure and result in unanticipated expenses for a builder orowner.

A previous attempt at an interlocking block design was presented in theSparlock system of Canada, which was introduced in the 1980's. However,the Sparlock system of blocks proved to be too heavy and used moreconcrete material than necessary, and saw only limited use within theconstruction industry. Sparlock remained unique for many years withoutany further development or changes. In 2005, other dry stack systemslike Haener, Azar blocks, and other construction blocks began to appearon the market, and still other systems have continued to be introduced.These other systems, however, all lack elements of compressive strengthand some are very weak. As a result, an improved interlockingconstruction block system is desired.

BRIEF SUMMARY

Described herein is an interlocking construction block system that canbe used to form a rigid structure without the use of a binding agentsuch as mortar during assembly. Advantageously, the interlockingconstruction block system requires no prior experience in masonry orother construction trades. Various embodiments of interlockingconstruction blocks can be combined modularly to create a structuralconfiguration in any length, width, or shape.

In an embodiment, the interlocking construction blocks may compriseinternal channels or conduits configured to receive piping, electricalwiring, reinforcing steel beams, rebar, and/or concrete within thechannels.

In an embodiment, the interlocking construction blocks may bemanufactured using any desired material. For example, the interlockingconstruction blocks may be manufactured with concrete. However,different materials, such as 3D-printed plastics, expanded polystyrene(EPS) foam or ceramic materials, may also be used.

The embodiments disclosed herein represent a standard family ofinterlocking construction blocks that meet the ASTM C90 guidelines forconcrete masonry units and can be interlocked in various configurationsto form a wide variety of structures.

In one embodiment, an interlocking construction block includes: a coresection having one or more wall sides, one or more interlocking sectionattachment sides, and one or more interlocking sections, each sectionincluding: a first interlocking portion, which is defined by a firstinterlocking portion attachment end, a first interlocking portion catchend, and a first interlocking portion catch; a second interlockingportion, which is defined by a second interlocking portion attachmentend, and a second interlocking portion key; and an interlocking sectionbridge capable of connecting the interlocking section to the one or moreinterlocking section attachment sides of the core section.

In one embodiment, the one or more wall sides of the core section of theinterlocking construction block further include a first wall side endand a second wall side end. In one embodiment, the one or moreinterlocking section attachment sides of the interlocking constructionblock further include a first interlocking section attachment side endand a second interlocking section attachment side end. In oneembodiment, the one or more interlocking sections of the interlockingconstruction block further include one or more negative space gapscapable of receiving an interlocking section of a second interlockingconstruction block.

In one embodiment, the interlocking construction block includes a coresection and two interlocking sections spaced approximately 180 degreesfrom each other, where the block is capable of creating a section of awall structure. In one example, the interlocking construction block isapproximately 8″ tall and is a stretcher block. In another example, theinterlocking construction block is approximately 4″ tall and is ahalf-stretcher block.

In one embodiment, the interlocking construction block includes a coresection and an interlocking section, where the block is capable ofcreating a wall end or window and door frames. In one embodiment, theinterlocking construction block includes a core section and twointerlocking sections spaced approximately 90 degrees from each other,where the block is capable of connecting two wall structures at acorner.

In some embodiments, the interlocking construction block includes a coresection and three interlocking sections each spaced approximately 90degrees from each other, where the block is capable of connecting threewall structures. In other embodiments, the interlocking constructionblock includes a core section and four interlocking sections each spacedapproximately 90 degrees from each other, where the block is capable ofconnecting four wall structures.

In one embodiment, the interlocking construction block further includesa reinforcing internal mesh cage. In another embodiment, the internalmesh cage is constructed from steel. In some embodiments, theinterlocking construction block as described herein is constructed froma cement mixture, aggregate, sand, water, or other raw materialshardened into concrete. \

In one embodiment, an interlocking construction block includes: a coresection having one or more wall sides, one or more interlocking sectionattachment sides, and one or more interlocking sections, each sectionhaving: a first interlocking portion, which is defined by a firstinterlocking portion attachment end, a first interlocking portion catchend, and a first interlocking portion catch; a second interlockingportion, which is defined by a second interlocking portion attachmentend; and a second interlocking portion key. The interlockingconstruction block further includes an interlocking section bridgecapable of connecting the interlocking section to the one or moreinterlocking section attachment sides of the core section, where thecore section is intersected by at least one of a central longitudinalhorizontal axis and a central lateral horizontal axis, and where aninternal channel is present along the central longitudinal horizontalaxis or the central lateral horizontal axis of the block and is capableof receiving an internal conduit or reinforcing member.

In one embodiment, an interlocking construction block system includestwo or more interlocking and self-aligning construction blocks, eachblock having: a core section including one or more wall sides, one ormore interlocking section attachment sides, and one or more interlockingsections, each section including: a first interlocking portion, which isdefined by a first interlocking portion attachment end, a firstinterlocking portion catch end, and a first interlocking portion catch;a second interlocking portion, which is defined by a second interlockingportion attachment end; and a second interlocking portion key, one ormore gaps capable of receiving a mating interlocking section, and aninterlocking section bridge capable of connecting the interlockingsection to the one or more interlocking section attachment sides of thecore section. The interlocking construction block system furtherincludes the first interlocking construction block capable of receivingthe interlocking section of a second interlocking construction blockwithin the gaps of the first interlocking construction block, therebyinterlocking the first and second interlocking construction blocks inthree axes.

In one embodiment, the three interlocking axes of the interlockingconstruction block system are a left/right axis, a front/back axis, andan up/down axis. In another embodiment, the core section of one or moreof the interlocking construction blocks of the interlocking constructionblock system is intersected by at least one of a central longitudinalhorizontal axis and a central lateral horizontal axis. In someembodiments, an internal channel is present along the centrallongitudinal horizontal axis of one of the one or more of theinterlocking construction blocks of the interlocking construction blocksystem, and where the internal channel is capable of receiving aninternal conduit or reinforcing member. In other embodiments, aninternal channel is present along both the central longitudinal andlateral horizontal axes of one of the one or more of the interlockingconstruction blocks the interlocking construction block system, andwhere the internal channel is capable of receiving an internal conduitor reinforcing member.

While various embodiments are described herein, the embodiments depictedshould not be viewed as exhaustive of all possible embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are illustrated by way of example in the accompanyingfigures, in which like reference numbers indicate similar parts, and inwhich:

FIG. 1 depicts a perspective view of an interlocking T-sectionconstruction block, which is used to connect three walls, in accordancewith one embodiment of the present disclosure;

FIG. 2 depicts a perspective view of an interlocking cross-sectionconstruction block, which is used to connect four walls, in accordancewith one embodiment of the present disclosure;

FIG. 3 depicts a perspective view of an interlocking corner-sectionconstruction block, which is used to connect two walls at a corner, inaccordance with one embodiment of the present disclosure;

FIG. 4 depicts a perspective view of an interlocking end-piececonstruction block, which is used to create wall ends, doors and windowframes, in accordance with one embodiment of the present disclosure;

FIG. 5 depicts a perspective view of an interlocking stretcherconstruction block, which is the main element of a wall, in accordancewith one embodiment of the present disclosure;

FIG. 6 depicts a perspective view of an interlocking half-stretcherconstruction block, which is an element to connect wall blocksvertically, in accordance with one embodiment of the present disclosure;

FIG. 7 depicts a perspective view comparing an interlocking stretcherand a half-stretcher construction blocks, in accordance with oneembodiment of the present disclosure;

FIG. 8 depicts a perspective and side view demonstrating horizontal andvertical interlocking of staggering stretcher and half-stretcher blocks,in accordance with one embodiment of the present disclosure;

FIG. 9 depicts a perspective view of an interlocking T-sectionconstruction block with an internal channel spanning the centralhorizontal axes of the block, in accordance with one embodiment of thepresent disclosure;

FIG. 10 depicts a perspective view of an interlocking cross-sectionconstruction block with an internal channel spanning the centralhorizontal axes of the block, in accordance with one embodiment of thepresent disclosure;

FIG. 11 depicts a perspective view of an interlocking corner-sectionconstruction block with an internal channel spanning the centralhorizontal axes of the block, in accordance with one embodiment of thepresent disclosure;

FIG. 12 depicts a perspective view of an interlocking end-piececonstruction block with an internal channel spanning the centrallongitudinal axis of the block, in accordance with one embodiment of thepresent disclosure;

FIG. 13 depicts a perspective view of an interlocking stretcherconstruction block with an internal channel spanning the centrallongitudinal axis of the block, in accordance with one embodiment of thepresent disclosure;

FIG. 14 depicts an alternate perspective view of an interlockingstretcher construction block with an internal channel spanning thecentral longitudinal axis of the block presented in FIG. 13.

FIG. 15 depicts a top view of an interlocking stretcher constructionblock with an internal channel spanning the central longitudinal axis ofthe block, in accordance with one embodiment of the present disclosure;

FIG. 16 depicts a side view providing comparison between channeled andnon-channeled embodiments of an interlocking construction block, inaccordance with one embodiment of the present disclosure;

FIG. 17 depicts a side view of a structure composed of differentconfigurations of channeled and non-channeled interlocking constructionblocks, in accordance with one embodiment of the present disclosure;

FIG. 18 depicts a perspective view of the structure from FIG. 17 withfull reinforcement steel rebar material placed within the internalchannels of the blocks, in accordance with one embodiment of the presentdisclosure;

FIG. 19 depicts a perspective cross-sectional view of the structure andfull reinforced steel rebar materials from FIG. 18, in accordance withone embodiment of the present disclosure;

FIG. 20 depicts a perspective view of another structure from FIG. 17with partial reinforced steel rebar materials placed within the internalchannels of the blocks, in accordance with one embodiment of the presentdisclosure;

FIG. 21 depicts a perspective cross-sectional view of the structure andpartial steel rebar materials from FIG. 20, in accordance with oneembodiment of the present disclosure;

FIG. 22 depicts top and side views of several embodiments ofinterlocking stretcher construction blocks, in accordance with oneembodiment of the present disclosure;

FIG. 23 depicts a perspective view of an interlocking T-sectionconstruction block, which is used to connect three walls, in accordancewith one embodiment of the present disclosure;

FIG. 24 depicts a perspective view of an interlocking cross-sectionconstruction block, which is used to connect four walls, in accordancewith one embodiment of the present disclosure;

FIG. 25 depicts a perspective view of an interlocking corner-sectionconstruction block, which is used to connect two walls at a corner, inaccordance with one embodiment of the present disclosure;

FIG. 26 depicts a perspective view of an interlocking end-piececonstruction block, which is used to create wall ends, doors and windowframes, in accordance with one embodiment of the present disclosure;

FIG. 27 depicts a perspective view of an interlocking stretcherconstruction block, which is the main element of a wall, in accordancewith one embodiment of the present disclosure;

FIG. 28 depicts a perspective view of an interlocking spacerconstruction block, which is an element to connect wall blocksvertically, in accordance with one embodiment of the present disclosure;

FIG. 29 depicts a perspective view of a first interlocking moldcomponent, in accordance with one embodiment of the present disclosure;

FIG. 30 depicts a top view of the first interlocking mold component ofFIG. 29, in accordance with one embodiment of the present disclosure;

FIG. 31 depicts a perspective view of a second interlocking moldcomponent, in accordance with one embodiment of the present disclosure;

FIG. 32 depicts a top view of the second interlocking mold component ofFIG. 31, in accordance with one embodiment of the present disclosure;

FIG. 33A depicts a breakaway perspective view of the first interlockingmold component of FIG. 29 connected to the second interlocking moldcomponent of FIG. 31 to create a two-part interlocking section mold, inaccordance with one embodiment of the present disclosure;

FIG. 33B depicts a connected view of the first interlocking moldcomponent of FIG. 29 connected to the second interlocking mold componentof FIG. 31 to create a two-part interlocking section mold, in accordancewith one embodiment of the present disclosure;

FIG. 34 depicts a perspective view of a central core of mold cavitydefining mold component, in accordance with one embodiment of thepresent disclosure;

FIG. 35 depicts a perspective view of an assembled female mold withcentral core, in accordance with one embodiment of the presentdisclosure;

FIG. 36 depicts a perspective view of a male mold corresponding to theassembled female mold of FIG. 35, in accordance with one embodiment ofthe present disclosure;

FIGS. 37A-I depict a method for manufacturing an interlockingconstruction block with the female mold of FIG. 35 and the male mold ofFIG. 36, in accordance with one embodiment of the present disclosure;

FIG. 38 depicts a top view of an assembled female mold for aninterlocking T-section construction block, in accordance with oneembodiment of the present disclosure;

FIG. 39 depicts a top view of an assembled female mold for aninterlocking cross-section construction block, in accordance with oneembodiment of the present disclosure;

FIG. 40 depicts a top view of an assembled female mold for aninterlocking corner-section construction block, in accordance with oneembodiment of the present disclosure;

FIG. 41 depicts a top view of an assembled female mold for aninterlocking end-piece construction block, in accordance with oneembodiment of the present disclosure;

FIG. 42 depicts a top view of an assembled female mold of aninterlocking stretcher construction block, in accordance with oneembodiment of the present disclosure;

FIG. 43 depicts a perspective view of a third interlocking moldcomponent, in accordance with one embodiment of the present disclosure;

FIG. 44 depicts a top view of the third interlocking mold component ofFIG. 43, in accordance with one embodiment of the present disclosure;

FIG. 45 depicts a perspective view of two first interlocking moldcomponents of FIG. 29 connected to the third interlocking mold componentof FIG. 43 to create a three-part repeating interlocking section mold,in accordance with one embodiment of the present disclosure;

FIG. 46 depicts a top view of an assembled female mold for a pluralityof interlocking stretcher construction blocks, in accordance with oneembodiment of the present disclosure;

FIG. 47 depicts a perspective view of an optional internal mesh cageused to produce reinforced concrete blocks, in accordance with oneembodiment of the present disclosure;

FIG. 48A depicts a top view of an interlocking wall structure withreinforced concrete blocks using the internal mesh cages inside theblock's concrete material of FIG. 47, in accordance with one embodimentof the present disclosure;

FIG. 48B depicts a front view of the interlocking wall structure withreinforced concrete blocks without reinforcing the wall of FIG. 48A, inaccordance with one embodiment of the present disclosure;

FIG. 48C depicts a perspective view of the interlocking wall structurewith reinforced concrete blocks without reinforcing the wall of FIG.48A, in accordance with one embodiment of the present disclosure;

FIG. 49 depicts an exploded view of the female mold of FIG. 35 and themale mold of FIG. 36, in accordance with one embodiment of the presentdisclosure;

FIG. 50 depicts an exploded view of the female mold of FIG. 35 and themale mold of FIG. 36 for manufacturing an interlocking constructionblock with a top channel, in accordance with one embodiment of thepresent disclosure;

FIG. 51 depicts an exploded view of the female mold of FIG. 35 and themale mold of FIG. 36 for manufacturing an interlocking constructionblock with a bottom channel, in accordance with one embodiment of thepresent disclosure;

FIG. 52 depicts a top view of an interlocking reinforced concreteT-section construction block with an internal mesh cage, in accordancewith one embodiment of the present disclosure;

FIG. 53 depicts a perspective view of the interlocking T-sectionconstruction block of FIG. 52, with the block's concrete material madetransparent to show the internal mesh cage inside the block, inaccordance with one embodiment of the present disclosure;

FIG. 54 depicts a top view of an assembled repeating female mold for aplurality of the interlocking T-section construction blocks of FIG. 52,in accordance with one embodiment of the present disclosure;

FIG. 55 depicts a perspective view of the assembled repeating femalemold of FIG. 54, in accordance with one embodiment of the presentdisclosure;

FIG. 56 depicts a top view of an interlocking reinforced concretecross-section construction block with an internal mesh cage, inaccordance with one embodiment of the present disclosure;

FIG. 57 depicts a perspective view of the interlocking reinforcedconcrete cross-section construction block of FIG. 56, with the block'sconcrete material made transparent to show the internal mesh cage insidethe block, in accordance with one embodiment of the present disclosure;

FIG. 58 depicts a top view of an assembled repeating female mold for aplurality of the interlocking cross-section construction blocks of FIG.56, in accordance with one embodiment of the present disclosure;

FIG. 59 depicts a perspective view of the assembled repeating femalemold of FIG. 58, in accordance with one embodiment of the presentdisclosure;

FIG. 60 depicts a top view of an interlocking reinforced concretecorner-section construction block with an internal mesh cage, inaccordance with one embodiment of the present disclosure;

FIG. 61 depicts a perspective view of the interlocking reinforcedconcrete corner-section construction block of FIG. 60, with the block'sconcrete material made transparent to show the internal mesh cage insidethe block, in accordance with one embodiment of the present disclosure;

FIG. 62 depicts a top view of an assembled repeating female mold for aplurality of the interlocking corner-section construction blocks of FIG.60, in accordance with one embodiment of the present disclosure;

FIG. 63 depicts a perspective view of the assembled repeating femalemold of FIG. 62, in accordance with one embodiment of the presentdisclosure;

FIG. 64 depicts a top view of an interlocking reinforced concreteend-section construction block with an internal mesh cage, in accordancewith one embodiment of the present disclosure;

FIG. 65 depicts a perspective view of the interlocking reinforcedconcrete end-section construction block of FIG. 64, with the block'sconcrete material made transparent to show the internal mesh cage insidethe block, in accordance with one embodiment of the present disclosure;

FIG. 66 depicts a top view of an assembled repeating female mold for aplurality of the interlocking end-section construction blocks of FIG.64, in accordance with one embodiment of the present disclosure;

FIG. 67 depicts a perspective view of the assembled repeating femalemold of FIG. 66, in accordance with one embodiment of the presentdisclosure;

FIG. 68 depicts a top view of an interlocking reinforced concretestretcher construction block with an internal mesh cage, in accordancewith one embodiment of the present disclosure;

FIG. 69 depicts a perspective view of the interlocking reinforcedconcrete stretcher construction block of FIG. 68, with the block'sconcrete material made transparent to show the internal mesh cage insidethe block, in accordance with one embodiment of the present disclosure;

FIG. 70 depicts a top view of an assembled repeating female mold for aplurality of the interlocking stretcher construction blocks of FIG. 68,in accordance with one embodiment of the present disclosure;

FIG. 71 depicts a perspective view of the assembled repeating femalemold of FIG. 70, in accordance with one embodiment of the presentdisclosure;

FIG. 72 depicts a top view of an interlocking reinforced concretehalf-stretcher construction block with an internal mesh cage, inaccordance with one embodiment of the present disclosure;

FIG. 73 depicts a perspective view of the interlocking reinforcedconcrete half-stretcher construction block of FIG. 72, with the block'sconcrete material made transparent to show the internal mesh cage insidethe block, in accordance with one embodiment of the present disclosure;

FIG. 74 depicts a top view of an assembled repeating female mold for aplurality of the interlocking half-stretcher construction blocks of FIG.72, in accordance with one embodiment of the present disclosure;

FIG. 75 depicts a perspective view of the assembled repeating femalemold of FIG. 74, in accordance with one embodiment of the presentdisclosure;

FIG. 76 depicts a top view of an interlocking reinforced concrete 9″spacer construction block with an internal mesh cage, in accordance withone embodiment of the present disclosure;

FIG. 77 depicts a perspective view of the interlocking reinforcedconcrete 9″ spacer construction block of FIG. 76, with the block'sconcrete material made transparent to show the internal mesh cage insidethe block, in accordance with one embodiment of the present disclosure;

FIG. 78 depicts a top view of an assembled repeating female mold for aplurality of the interlocking stretcher construction blocks of FIG. 76,in accordance with one embodiment of the present disclosure;

FIG. 79 depicts a perspective view of the assembled repeating femalemold of FIG. 78, in accordance with one embodiment of the presentdisclosure;

FIG. 80 depicts an illustration of how one goes about performing theASTM C90 calculation; and

FIG. 81 depicts an illustration of the data of the ASTM C90 blockscompared to the currently disclosed (GT) block embodiments.

DETAILED DESCRIPTION OF DRAWINGS

While the making and using of various embodiments of the presentdisclosure are discussed in detail below, it should be appreciated thatthe present disclosure provides many applicable inventive concepts thatcan be embodied in a wide variety of specific contexts. The specificembodiments discussed herein are merely illustrative of specific ways tomake and use the disclosure and do not limit the scope of thedisclosure.

Interlocking Construction Blocks

FIG. 1 depicts a perspective view of an interlocking construction block100. While the specific geometry of the block 100 is described below, itis to be understood that the blocks described in FIGS. 1-6, FIGS. 23-28,and FIGS. 52-79 are families of blocks utilizing interlocking geometryso that each of the disclosed construction blocks may interlock andself-align with each other without the use of a binding agent such asmortar during assembly. That is, the geometric sections described belowin relation to FIG. 1 are also present in the blocks depicted in FIGS.2-6, FIGS. 23-28, and FIGS. 52-79 so that various blocks within a familyof blocks may interlock with each other without the use of a bindingagent such as mortar during assembly.

The block 100 depicted in FIG. 1 is a T-section block that comprisesfour sections: a core section 110 and three interlocking sections 120,130, and 140, each being of a preferable material, thickness, andheight. The T-section block 100 may be an interlocking constructionblock suitable for connecting three walls. In an embodiment, the threeinterlocking sections 120, 130, and 140 may be spaced 90 degrees fromeach other about the core section 110, although the interlockingsections may be spaced apart from each other in any orientation.

The core section 110 may comprise a flat wall side 111 and threeinterlocking section attachments 112, 113, and 114, each of which may beused to connect the interlocking sections 120, 130, and 140 to the coresection 110. Geometrically, the interlocking sections 120, 130, and 140may be sized and shaped such that the sections form repeating patternsof negative and positive space that may interlock with similarinterlocking sections in the next interlocking block formed in astructure.

The wall side 111 may preferably be a vertical and rectangular plane ofmaterial extending from a first wall side end 115 to a second wall sideend 116 and may generally define part of an outer surface of a structuremanufactured from blocks 100 and/or other embodiments described herein.

From the wall side 111, the attachment section 114 may make a 90-degreecorner with the first wall side end 115 but may also be a continuousextension of the first wall side end 115. The interlocking sectionattachment 114 may be extend from a first interlocking attachment sideend 117 to a second interlocking attachment side end 118. The firstinterlocking attachment side end 117 may extend from the wall side 111proximate to the first wall side end 115 at a right angle to form anadjacent side of the core section 110. The second interlocking sectionattachment end 118 may curve away from the core section 110 at a rightangle and may serve as a connection point between the interlockingsection 120 and the core section 110.

As shown in FIG. 1, the interlocking attachment sides 113 and 112 mayfunction similarly to the interlocking attachment side 114 discussedabove and may facilitate connection of the interlocking sections 130 and140, respectively, to the core section 110, thereby giving core section110 its rectangular T-section shape comprising three interlockingsections and one core section.

While the features of the interlocking section 130 are described below,it is to be understood that with the repeating geometry of theinterlocking blocks, the features of the interlocking sections 120 and140 would be similar. The interlocking section 130 may be comprised of afirst interlocking portion 131 and a second interlocking portion 135,each defining a positive space and creating a negative spacetherebetween.

The first interlocking portion 131 may comprise a wall extending fromthe core section 110 at a first interlocking portion attachment end 132,extending along a first interlocking portion catch end 133, and endingat a first interlocking portion catch 134. The first interlockingportion attachment end 132 connects the first interlocking portion 131to the core section 110 by connecting to the interlocking attachmentside 112 and may additionally connect the first interlocking portion 131to the second interlocking portion 135 via an interlocking sectionbridge 138. The first interlocking catch end 133 may be opposite firstinterlocking portion attachment end 132 and may extend away from thecore section 110. The first interlocking portion catch 134 may protrudeat a right angle from first interlocking portion catch end 133 and mayfunction as part of the interlocking construction block system describedbelow.

The second interlocking portion 135 may be comprised of a secondinterlocking portion attachment end 137 and a second interlockingportion key 136. The second interlocking portion attachment end 137 maybe connected to the interlocking section 120 at the interlockingattachment side 113 and to the first interlocking portion 131 via theinterlocking formation bridge 138. Extending away from the secondinterlocking portion attachment end 137 may be the second interlockingportion key 136, which may also function as part of the interlockingconstruction block system described below.

As depicted in FIG. 1, and with reference to the interlocking block 100,it should be understood that the interlocking sections 120, 130, and 140may be identical in shape and function and that the description of oneof these sections is analogous to the others, though this may notnecessarily be the case for other embodiments.

A negative space gap 152 may be formed between the first and secondinterlocking portions 131 and 135. The gap 152 may serve as a slot intowhich a second interlocking portion key of an interlocking section of aseparate block may interlock. Additionally, the second interlockingportion key 136 may be placed into a gap of an adjacent block in orderto facilitate interlocking of the two blocks.

In a similar manner, a negative space gap 151 may be formed between thesecond interlocking portion 135 and the interlocking section attachmentside 113. The gap 151 may serve as a slot into which the firstinterlocking portion catch belonging to another block may fit.Additionally, the first interlocking portion catch 134 may be placedinto a gap of an adjacent block to interlock the blocks.

Combined with the geometry of the first interlocking portion 131 and thesecond interlocking portion 135, the geometry of the gaps 151 and 152may create repeating geometric patterns that allow adjacent interlockingblocks to interlock with each other without the use of a binding agentsuch as mortar during assembly. In any particular interlocking block,the first interlocking portion catch and the second interlocking portionkey, with the defined positive spaces creating negative gaps, results ina strong interlocking formation which may allow adjacent interlockingblocks to be secured to one another, while preventing independentmovement, when interlocked.

Each of the elements described above in relation to the block 100 may bepresent in one or more of the following embodiments. These elements mayinclude core sections, interlocking sections, wall sides, interlockingsection attachment sides, first wall side ends, second wall side ends,interlocking attachment sides, first and second interlocking attachmentside ends, first and second interlocking portions, first and secondinterlocking portion catch ends, interlocking section bridges, first andsecond interlocking portion catches, interlocking portion keys,interlocking formation bridges, and gaps. The geometry of each of theelements of the blocks described below are such that various blocks canbe interlocked to create any size or shape of structure desired.

FIG. 2 depicts a perspective view of an interlocking cross-sectionconstruction block 200, which is used to connect four walls, inaccordance with one embodiment of the present disclosure. The block 200may be similar in design and functionality to the block 100 from FIG. 1,but may contain four interlocking sections rather than three and no wallsides. The block 200 may be suitable for joining four walls. In anembodiment, the four interlocking sections may be spaced 90 degrees fromeach other about the core section.

As such, block 200 is comprised of a core section 220 which is adjoinedto four interlocking sections 210, 211, 212, and 213. The core section220 may be defined by four interlocking section attachment sides 221,222, 223, and 224, which are disposed in a cross-shaped configuration.The interlocking section attachment sides as well as the interlockingsections interact and function identically as described above inreference to block 100. The design of block 200 allows one to extend aninterlocking construction block structure in four orthogonal directions,for example at the intersection of internal partition walls within astructure.

FIG. 3 depicts a perspective view of an interlocking corner-sectionconstruction block 300, which is used to connect two walls at a corner,in accordance with one embodiment of the present disclosure. The block300 may comprise a core section 320 as well as two interlocking sections310 and 311. The two interlocking sections 310 and 311 may be spaced 90degrees from each other about the core section to form a corner.

The core section 320 may comprise two interlocking section attachmentsides 321 and 322 disposed adjacent to one another, as well as two wallsides 323 and 324, which are also disposed adjacent to one another, suchthat the two interlocking sections 310 and 311 and the interlockingsection attachment sides 321 and 322 form a right angle to one another.The configuration of block 300 may be used, for example, at theintersection of two walls to form a connection corner of a structure.

FIG. 4 depicts a perspective view of an interlocking end-piececonstruction block 400, which is used to create wall ends, doors andwindow frames, in accordance with one embodiment of the presentdisclosure. The block 400 may comprise a core section 420 and aninterlocking section 410. The core section 420 may further comprise aninterlocking section attachment side 424 as well as three wall sides421, 422, and 423. The configuration of the block 400 facilitates anend-piece interlocking construction block 400 which may be used, forexample, as wall ends as well as for window and door frames.

FIG. 5 depicts a perspective view of an interlocking stretcherconstruction block 500, which is the main element of a wall, inaccordance with one embodiment of the present disclosure. The block 500may comprise a core section 520 as well as two interlocking sections 510and 511 that are disposed opposite one another. The core section 520 mayfurther comprise interlocking section attachment sides 521 and 522 aswell as wall sides 523 and 524. Interlocking section attachment sides521 and 522 may also disposed opposite one another and adjacent to thewall sides 523 and 524.

The configuration of block 500 facilitates a stretcher interlockingconstruction block which may be preferably used, for example, to extenda wall of a structure in a chosen length and/or direction. In anembodiment, the block 500 may measure 12″ in length and 8″ in height.

FIG. 6 depicts a perspective view of an interlocking half-stretcherconstruction block 600, which is an element to connect wall blocksvertically, in accordance with one embodiment of the present disclosure.The configuration of the block 600 may be the same as that of the block500, with a core section and two interlocking sections, except that theblock 600 may half the height of the block 500. In an embodiment, theblock 600 may measure 12″ in length and 4″ in height.

A perspective view comparing the heights of the stretcher block 500 andthe half-stretcher block 600 can be seen in FIG. 7. In an embodiment,the stretcher block 500 may be 8″ tall while the half-stretcher block600 may be 4″ tall. While the half-stretcher blocks 600 are disclosed,it is to be understood that any of the blocks depicted in FIGS. 1-5 maybe manufactured in regular height or half height.

By using a combination of stretcher blocks 500 and half-stretcher blocks600, one may stagger multiple interlocking construction blocks within awall to interlock them along three axes: left/right, front/back, andup/down. An exemplary embodiment depicting this process can be seen inFIG. 8, wherein blocks 801 and 802 are half-stretcher blocks but theremaining blocks depicted are stretcher blocks. By utilizing thedepicted alternating interlocking pattern between the seams of theblocks in the wall, a “woven” effect is created, both vertically andhorizontally. This allows the blocks to lock in place and allows evendistribution of structural weights and stresses, even during seismic orwind events.

FIG. 9 depicts a perspective view of interlocking T-section constructionblocks 900 and 950 with internal channels spanning the centralhorizontal axes of the blocks, in accordance with one embodiment of thepresent disclosure. Blocks 900 and 950 are similar in configuration andfunction to the T-section block 100 depicted in FIG. 1, but with theaddition of internal channels 901 and 902 added along the centralhorizontal longitudinal and lateral axis of the blocks, respectively.Channels 901 and 902 are defined by U-shaped grooves 903 extending fromthe vertical center of the block outward towards the top or bottomsurfaces of the blocks 900 and 950. An internal channel may be added toeither the top (block 900) or bottom (block 950) half of an interlockingconstruction block, depending on the needs of the end user and on localbuilding code requirements. Block 900 has internal channels 901 and 902extending from its vertical center to its top surface, while block 950has internal channels 951 and 952 extending from its vertical centerdown to its bottom surface. These channels may be used, for example, toaccommodate horizontal plumbing, electrical tubing and/or horizontalsteel rebar reinforcement within a structure, or any other materialpreferable to the user depending upon local building code requirements.

FIGS. 10-13 depict perspective views of previously presentedinterlocking construction blocks with additional internal channelssimilar to those described in FIG. 9 added. FIG. 10 depicts twoembodiments of cross-section interlocking construction blocks 1000 and1050 each with internal channels running along its central longitudinaland lateral axes, disposed on either the top or bottom half of theblocks. FIG. 11 depicts two embodiments of corner-section interlockingconstruction blocks 1100 and 1150 each with internal channels runningalong its central longitudinal and lateral axes, disposed on either thetop (block 1100) or bottom (block 1150) half of the blocks. FIG. 12depicts two embodiments of end-piece interlocking construction blocks1200 and 1250 each with an internal channel running along its centrallongitudinal axis, disposed on either the top (block 1200) or bottom(block 1250) half of the blocks. FIG. 13 depicts two embodiments ofstretcher interlocking construction blocks each with an internal channelrunning along its central longitudinal axis, disposed on either the topor bottom half of the blocks.

FIG. 14 depicts an alternate perspective view of the interlockingstretcher construction block 1300 depicted in FIG. 13 with an internalchannel spanning the top half of central longitudinal axis of the block1300. As seen in FIG. 14, the U-shaped internal channel runninglongitudinally through the top half of the block is more readilyapparent and is operable to accommodate horizontal plumbing, electricaltubing and/or horizontal steel rebar reinforcement within a structure,or any other material preferable to the user depending upon localbuilding code requirements.

FIG. 15 depicts a top view of the interlocking stretcher constructionblocks 1300 and 1350 with internal channels spanning the centrallongitudinal axis of the block, in accordance with one embodiment of thepresent disclosure. As seen in FIG. 15, internal channels can bemanufactured to coordinate with any orientation of a proposed orexisting structure. Block 1300 may comprise a top channel, while block1350 may comprise a bottom channel.

FIG. 16 depicts a side view providing comparison between channeled andnon-channeled embodiments of interlocking construction blocks 500, 1300,and 1350, in accordance with one embodiment of the present disclosure.Looking down the longitudinal axis of interlocking stretcherconstruction blocks to offer a comparison between various channeledembodiments and non-channeled embodiments (500) of the disclosedinterlocking construction blocks. Block 1300 may comprise a top channel,while block 1350 may comprise a bottom channel.

FIG. 17 depicts a side view of a structure composed of differentconfigurations of channeled and non-channeled interlocking constructionblocks, in accordance with one embodiment of the present disclosure. Astructure 1700 is composed exclusively with channeled interlockingconstruction blocks, while a structure 1750 is composed of a combinationof channeled and non-channeled blocks, and serves to illustrate that anypreferable combination of channeled and non-channeled blocks may beutilized depending on the needs of the user and on local building coderequirements.

FIG. 18 depicts a perspective view of the structure 1700 from FIG. 17with full reinforcement steel rebar material placed within the internalchannels of the blocks, while FIG. 19 depicts a perspectivecross-sectional view of the structure and full reinforced steel rebarmaterials from FIG. 18, in accordance with one embodiment of the presentdisclosure. In both FIGS. 18 and 19, reinforcing steel bars are placedwithin the internal channels of the structure and run longitudinallyalong the structure while scaffolding is placed within the hollow coresections of the blocks and runs vertically up through the structure1700. These additional materials serve to provide added strength to thestructure 1700.

FIG. 20 depicts a perspective view of the structure 1750 from FIG. 17with partial reinforced steel rebar reinforcement materials placedwithin the internal channels of the blocks, while FIG. 21 depicts aperspective cross-sectional view of the structure and partial steelrebar materials from FIG. 20, in accordance with one embodiment of thepresent disclosure. In both FIGS. 20 and 21, plumbing and electricaltubing have been placed within the internal channels of the structure,providing demonstration of the array of possible combinations and usesof interlocking construction blocks with or without internal channels,depending on the preference of the user and local building coderequirements.

In addition to providing reinforcing material within channels that spanbetween multiple interlocking construction blocks to reinforce astructure such as a wall, each individual block may also be reinforced.FIG. 47 depicts a perspective view of an optional internal mesh cage4700, in accordance with one embodiment of the present disclosure. Theinternal mesh cage 4700 may be added to the interlocking block duringthe mold process (discussed below), and may be shaped and sized toreinforce substantially all of the interlocking block. In an embodiment,the internal mesh cage 4700 may be shaped and placed proximate to theouter perimeter of the interlocking block, although it otherembodiments, it may be shaped and placed anywhere within theinterlocking block. The internal mesh cage 4700 may be made from steelmesh, carbon fiber, or any other material suitable for providingreinforcement to the interlocking block.

FIGS. 48A, 48B, and 48C depict top, front, and perspective views,respectively, of an interlocking wall structure 4800 with internal meshcages 4700 of FIG. 47, in accordance with one embodiment of the presentdisclosure. As shown in FIG. 48A-C, five columns of interlockingstretcher and half-stretcher construction blocks 4802 are interlocked,forming the wall structure 4800. Each of the interlocking constructionblocks 4802 have internal mesh cages 4700, reinforcing the structure ofeach individual block 4802.

FIG. 22 depicts top and side views of several embodiments ofinterlocking stretcher construction blocks 2200, in accordance with oneembodiment of the present disclosure. These exemplary embodiments ofinterlocking stretcher construction blocks comprise a variety ofdifferent total lengths and widths. These embodiments serve todemonstrate that the interlocking construction blocks previouslypresented herein are not exhaustive of the possible configurations andembodiments and that interlocking construction blocks can bemanufactured to any specifications desired by the user and on localbuilding code requirements. Any number of repeating geometric patternsmay be used to create interlocking construction blocks as long as thepositive spaces defining negative spaces repeat in each interlockingsection. For example, specific geometries of interlocking sections aredepicted in FIGS. 23-28, below. The geometries of FIGS. 23-28, whiledifferent than those depicted in FIGS. 1-6, are similarly repeating andallow to the disclosed blocks to interlock with adjacent blocks.

FIG. 23 depicts a perspective view of an interlocking T-sectionconstruction block 2300, which is used to connect three walls, inaccordance with one embodiment of the present disclosure. FIG. 24depicts a perspective view of an interlocking cross-section constructionblock 2400, which is used to connect four walls, in accordance with oneembodiment of the present disclosure. FIG. 25 depicts a perspective viewof an interlocking corner-section construction block 2500, which is usedto connect two walls at a corner, in accordance with one embodiment ofthe present disclosure. FIG. 26 depicts a perspective view of aninterlocking end-piece construction block 2600, which is used to createwall ends, doors and window frames, in accordance with one embodiment ofthe present disclosure. FIG. 27 depicts a perspective view of aninterlocking stretcher construction block 2700, which is the mainelement of a wall, in accordance with one embodiment of the presentdisclosure. FIG. 28 depicts a perspective view of an interlocking spacerconstruction block 2800, in accordance with one embodiment of thepresent disclosure.

The interlocking construction blocks of FIGS. 23-28, described below,may be similar to the interlocking construction blocks depicted in FIGS.1-6, but may include different geometries of interlocking features ineach of the interlocking sections. Specifically, the geometry of eachinterlocking sections may utilize less building material by reducing thesize of the interlocking portion catch ends, the interlocking portionkeys, and the interlocking portion attachment ends, thereby making theinterlocking construction blocks cheaper to make and more lightweight.The remaining disclosure of FIGS. 1-6 is herein incorporated byreference in relation to FIGS. 23-28.

It is to be understood that in order to interlock and self-alignproperly, different blocks within a family of an interlockingconstruction block system will utilize the same geometry of interlockingportions. That is, the interlocking construction blocks of FIGS. 1-6 mayinterlock and self-align with each other without the use of a bindingagent such as mortar during assembly, while the interlockingconstruction blocks of FIGS. 23-28 may interlock and self-align witheach other without the use of a binding agent such as mortar duringassembly. But blocks with different interlocking section geometries maynot interlock and self-align with each other without the use of abinding agent such as mortar during assembly.

In each of the embodiments described in relation to FIGS. 1-28, theinterlocking constructions blocks are operable to interlock with eachother in at least three directions. The blocks may interlock along threeaxes: a left/right axis, a front/back axis, and an up/down axis. Each ofthe various configurations of blocks can be manufactured in differentwidths to conform to building code requirements around the world.

The interlocking construction blocks, such as the stretcher block 500and the half-stretcher block 600, can be manufactured in the standard12″ length, but can also be manufactured in special 6″ lengths or in 8″and 9″ extension lengths. By configuring the blocks in 6″, 8″, 9″, and12″ lengths, a combination of blocks can be used to create any length ofwall in one inch increments. For example, a 3′ section may be createdwith three 12″ blocks. A 3′ 1″ section may be created with one 12″block, one 9″ block, and three 8″ blocks. A 3′ 2″ section may be createdwith one 12″ block, two 9″ blocks, and two 8″ blocks. A 3′ 2″ sectionmay be created with one 12″ block and three 9″ blocks. A 3′ 4″ sectionmay be created with two 12″ blocks and two 8″ sections. Any other lengthof section may be created in this manner in one inch increments. Byallowing any length of wall to be created, the interlocking constructionblocks advantageously may be used for both infill and retrofitting inaddition to new construction. In addition, the interlocking constructionblocks can advantageously be used for infrastructure such as building aroadway over a streambed.

Similarly, any width of wall structure can be made using various shapesand sizes of the disclosed interlocking construction blocks, as well asany size and shape of structure. For example, the disclosed interlockingconstruction blocks may be used to create either reinforced ornon-reinforced walls of a house or office or other structure.

The standard thickness of an interlocking construction block may be 6″,which surpasses the strength requirements for six-inch and eight-inchstandard ASTM C90 concrete masonry units (CMU), but in otherembodiments, the block may be 5″ or 8″ thick or any other thicknessdesired. The blocks may also be manufactured with different materialdensities for structural and non-structural walls. In addition tomanufacturing individual blocks of various widths, the interlockingconstruction blocks can be interlocked together to create a wall of anythickness by allowing one or more rows of blocks to interlock together.

The disclosed interlocking construction blocks may be constructed from acement mixture, aggregate, sand, and/or water and may meet or exceedASTM C90 requirements while requiring less material to construct. Inorder to calculate the ASTM C90 requirements, the following calculationis performed as shown in FIG. 80.

And the ASTM C90 requirements for the minimum thickness of face shellsand webs for hollow units are listed in Table 1 below:

TABLE 1 ASTM C90 Minimum Thickness of Face Shells and Webs for HollowUnits. Web thickness Nominal Face shell Equivalent width Thickness B, C,web thickness, of units, minimum, Webs B, C, D in./linear ft E in. (mm)in. (mm) in. (mm) (mm/linear m) 3 (76.2) & 4 (102) ¾ (19) ¾ (19) 1⅝(136) 6 (152) 1 (25)D 1 (25) 2¼ (188) 8 (203) 1¼ (32)D 1 (25) 2¼ (188)18 (254) and greater 1¼ (32) 1⅛ (29) 2½ (209) A. Average of measurementson a minimum 3 units when measured as described in Test Methods C 140.B. When this standard is used for units having split surfaces, a maximumof 10% of the split surface is permitted to have thickness less thanthose shown, but not less than ¾ in. (19.1 mm). When the units are to besolid grouted, the 10% limit does not apply and Footnote C establishes athickness requirement for the entire face shell. C. When the units areto be solid grouted, minimum face shell and web thickness shall be notless than ⅝ in. (16 mm). D. The minimum web thickness for units webscloser than 1 in. (25.4 mm) apart shall be ¾ in. (19.1 mm). E.Equivalent web thickness does not apply to the protion of the unit to befilled with grout. The length of that portion shall be deducted from theoverall length of the unit for the calculation of the equivalent webthickness.

Comparing ASTM C90 blocks and the disclosed interlocking constructionblocks for a 1.2 m wall structure, four of the disclosed blocks have alarger cross-section area than three regular ASTM C90 blocks, whichresults in the disclosed blocks providing more than 10% more compressionstrength with the same mix and density. In addition, the four disclosedblocks would have more material than the three ASTM C90 blocks, but theamount of mortar needed to affix the ASTM C90 blocks would be greaterthan the material difference. As such, the disclosed blocks wouldrequire less overall material and would be lighter weight. A comparisonof ASTM C90 blocks to the disclosed (GT) blocks is shown in shown inFIG. 81.

As shown above, the ground area that a 1.2 m wall structure comprisingfour of the disclosed blocks cover would be 0.18 m² (1.2 m long×0.15 mwide), while the area covered for the ASTM C90 blocks would be 0.2436 m²(1.2 m long×0.203 m wide). This results in more than 25% savings ofground area necessary to build a stronger wall structure.

In addition to the block configurations depicted in FIGS. 1-28, a widerange of auxiliary blocks can be manufactured in different lengths,widths, and densities depending on developer needs and local buildingcode requirements.

Advantageously, the disclosed interlocking block system is a complete,integrated family of blocks that allow for a full connection for anywall in any direction. In addition, specialty blocks can be integrateddepending on a builder's unique desires or needs. The disclosed blocksystem use less overall material to manufacture and requires less totalmaterial in the wall because mortar is not required during assembly. Thedisclosed blocks are also lighter than traditional concrete blocks withmortar, which results in the entire wall being lighter, requiring lesssoil preparation and a less costly foundation. Because the disclosedblocks are self-aligning and interlocked in three axes, not only ismortar not required during assembly, but no adjustment of the blocks isrequired. Thus, the disclosed blocks do not require skilled labor, whichreduces the number of labor hours and cost per man hour. And because thedisclosed blocks are faster to construct and self-align, projects can befinished up to 75% more quickly. And compared to standard ASTM C90 CMUconstruction, structures made with the disclosed blocks are stronger andless costly to reinforce.

Modular Mold Sets for Manufacturing Interlocking Construction Blocks

The modular mold sets described in relation to FIGS. 29-47 below may beused to manufacture one or more of the interlocking construction blocksdescribed in relations to FIGS. 1-28. In some embodiments, a mold setgenerally includes male mold part(s) and female mold part(s). In otherwords, the male mold and the female mold are parts or portions of themold set. For example, the male mold may also be referring to the malepart or the male portion of the mold set while the female mold may alsobe referring to the female part or the female portion of the mold set.Each of the male mold and the female mold can be modular in nature andcollectively form the modular mold set.

FIG. 29 depicts a perspective view and FIG. 30 depicts a top view of afirst interlocking mold component 2900, in accordance with oneembodiment of the present disclosure. For ease of reference, in severalsubsequent figures, the first interlocking mold component 2900 may alsobe labeled as “1.”

As seen in FIG. 29, the first interlocking mold component 2900 may be agenerally vertical mold and may comprise a rear wall 2902, opposing sidewalls 2904 and 2906, and a front wall 2908. The rear wall 2902 maydefine a flat surface that is operable to connect to a side connectionwall of the female mold, as described below. The opposing side walls2904 and 2906 may define flat surfaces parallel to each other and atright angles to the rear wall 2902. The front wall 2908 may also definea flat surface parallel to the rear wall 2902 and a geometric recess2910 created within the front wall 2908. The geometric recess 2910 maybe sized and shaped to form at least a portion of the secondinterlocking portion of an interlocking block that is created with themold set.

The rear wall 2902 may comprise a plurality of apertures (not shown)spaced across the flat surface of the rear wall 2902. One or more ofthese apertures may extend across the first interlocking mold component2900 from the rear wall 2902 to the front wall 2908, creating apertures2912 as shown in FIG. 29. The plurality of apertures may be used toconnect the first interlocking mold component 2900 to a secondinterlocking mold component and to a side connection wall of the femalemold, as described below.

In an embodiment, the mold 2900 may have outer dimensions ofapproximately 80 mm by 65 mm, and more specifically, may have outerdimensions of approximately 82.5 mm by 63 mm. In an embodiment, the mold2900 may weigh between 5 and 8 kilograms, and more specifically, mayweigh approximately 7.34 kilograms.

FIG. 31 depicts a perspective view and FIG. 32 depicts a top view of asecond interlocking mold component 3100, in accordance with oneembodiment of the present disclosure. For ease of reference, in severalsubsequent figures, the second interlocking mold component 3100 may alsobe labeled as “2.” In addition, because the first interlocking moldcomponent 2900 and the second interlocking mold component 3100 combineto create an interlocking section of an interlocking construction block,the relative terms of front, rear, and side walls will describe walls inthe same orientation when the first interlocking mold component 2900 andthe second interlocking mold component 3100 are connected to each other.

As seen in FIG. 31, the second interlocking mold component 3100 may be agenerally vertical mold and may comprise a rear wall 3102, a side wall3106, and a front wall 3108. The rear wall 3102 may define a flatsurface that is operable to connect to a side connection wall of thefemale mold, as described below. The side wall 3106 may define a flatsurface at a right angle to the rear wall 3102 and may be operable toform an end of the female mold, as described below. The front wall 2908may also define a flat surface parallel to the rear wall 3102. Thesecond interlocking mold component 3100 may further comprise a geometricprotrusion 3104. The geometric protrusion 3104 may be sized and shapedto form a gap between the first and second interlocking portions of aninterlocking block that is created with the mold set. A geometric recess3110 may be sized and shaped to form a first interlocking portion catchof an interlocking block that is created with the mold set.

The rear wall 3102 may comprise a plurality of apertures 3112 that mayextend across the second interlocking mold component 3100 from the rearwall 3102 to the front wall 3108, as shown in FIG. 31. The plurality ofapertures 3112 may be used to connect the second interlocking moldcomponent 3100 to a side connection wall of the female mold, asdescribed below. Further, the geometric protrusion 3104 may comprise aplurality of apertures 3114 opposite the geometric recess 3110 that mayextend within, but not through, the geometric protrusion 3104. Theseapertures 3114 may be used to connect the first interlocking moldcomponent 2900 to the second interlocking mold component 3100.

In an embodiment, the mold 3100 may have outer dimensions ofapproximately 150 mm by 80 mm, and more specifically, may have outerdimensions of approximately 151 mm by 82.5 mm. In an embodiment, themold 3100 may weigh between 10 and 12 kilograms, and more specifically,may weigh approximately 11.64 kilograms.

FIG. 33A depicts a breakaway perspective view and FIG. 33B depicts aconnected view of the first interlocking mold component of FIG. 29connected to the second interlocking mold component of FIG. 31 to createa two-part interlocking section mold 3300, in accordance with oneembodiment of the present disclosure.

When the apertures 2912 of the first interlocking mold component 2900and the apertures 3114 of the second interlocking mold component 3100are aligned, threaded bolts 3302 may be inserted through washers 3304and threaded into the apertures 2912 of the first interlocking moldcomponent 2900 and then threaded into the apertures 3114 of the secondinterlocking mold component 3100. Once connected, the two-part mold 3300may be used to create an interlocking section of an interlockingconstruction block. This two-part mold 3300 using molds 1 and 2 may beused to create the interlocking section for molds for any shape and sizeof interlocking construction block by using a combination of two-partmolds, connecting side walls, and connecting end walls.

FIG. 34 depicts a perspective view of a central core of mold cavitydefining mold component 3400, in accordance with one embodiment of thepresent disclosure. In some embodiments, a central core of mold cavitydefining mold component 3400 may be desired in order to create anegative space in the center of an interlocking construction block,which decreases the weight of and the overall material necessary to formthe interlocking construction block. The central core of mold cavitydefining mold component 3400 may be made in any shape that is thedesired shape of the central cavity of the interlocking constructionblock. The central core of mold cavity defining mold component 3400 maycomprise a rear wall 3402, geometric side walls 3404 and 3406, and afront wall 3408. The rear wall 3402 and the front wall 3408 may be flatsurfaces, while the geometric side walls 3404 and 3406 may be shaped togenerally mirror the shape of the interlocking section features of thetwo-part mold 3300 of FIG. 33. In an embodiment, the central core ofmold cavity defining mold component 3400 may be shaped to additionallyinclude sections that correspond to the shape of the two-part mold 3300of FIG. 33B. The central core of mold cavity defining mold component3400 may further comprise one or more tabs 3410 extending from an uppersurface of the rear wall 3402 and the front wall 3408. The one or moretab 3410 may be used to hold the central core of mold cavity definingmold component 3400 relative to connecting side walls of the femalemold, as described below.

FIG. 35 depicts a perspective view of an assembled female mold 3500, inaccordance with one embodiment of the present disclosure. The depictedfemale mold 3500 may be use to form an interlocking stretcherconstruction block, but as seen in FIGS. 38-41 below, various shapes andsizes of female molds may be used to form different sizes and shapes ofinterlocking construction blocks.

The assembled female mold 3500 comprises two of the two-part molds 3300of FIG. 33, each comprising a first interlocking mold component 2900 anda second interlocking mold component 3100. The two two-part molds 3300may be connected to each other with rear connecting side wall 3502 andfront connecting side wall 2508. The side walls of the secondinterlocking mold components 3100 may form the end walls of theassembled female mold 3500 while the end walls of the first interlockingmold components 2900 and second interlocking mold components 3100 may beconnected to the first and second connecting side walls 2502 and 2508with threaded bolts (not shown) through apertures 3512, 3513, and 3514.

Apertures 3513 and 3514 may be a plurality of apertures each aligned ina vertical orientation along the vertical edges of the first and secondconnecting side walls 2502 and 2508, while apertures 3512 may be aplurality of apertures in a grid-like pattern proximate to the verticalapertures 3513. The location of each of the apertures allows theconnecting side walls 2502 and 2508 to be used to make a wide variety ofshapes and sizes of interlocking construction blocks without requiringspecific connecting sides, thereby increasing the modularity of the moldsets.

For example, threaded bolts may be threaded through apertures 3512 inthe connecting side walls 2502 and 2508, threaded into the apertures2912 of the first interlocking mold component 2900 and then threadedinto the apertures 3114 of the second interlocking mold component 3100,as described in FIG. 33, connecting the connecting side walls 2502 and2508 to the first interlocking mold components 2900 and the secondinterlocking mold components 3100. To further strengthen the assembledfemale mold 3500, threaded bolts (not shown) may also be threadedthrough apertures 3513 and 3514 and into apertures 3112 of the secondinterlocking mold components 3100.

The connecting side walls 2502 and 2508 may further comprise one or morenotches 3510 along upper horizontal edges of the connecting side walls.These notches 3510 may be sized and shaped to interact with the tabs3410 of the central core of mold cavity defining mold component 3400.

If a central cavity is desired in the resulting manufacturedinterlocking construction block, the central core of mold cavitydefining mold component 3400 may be used. In an embodiment, the centralcore of mold cavity defining mold component 3400 is removable and may beinserted into the center cavity of the female mold 3500. The one or moretabs 3410 of the central core of mold cavity defining mold component3400 may rest in the one or more notches 3510 of the connecting sidewalls 3502 and 3508. In a different embodiment, the central core of moldcavity defining mold component 3400 may be a unitary part of the femalemold 3500 and the one or more tabs 3410 of the central core of moldcavity defining mold component 3400 may rest in the one or more notches3510 of the connecting side walls 3502 and 3508, if necessary.

Because the tabs 3410 may be necessary to connect the central core ofmold cavity defining mold component 3400 to the connecting side walls3502 and 3508, the overall height of the female mold 3500 may be greaterthan the desired finished height of the interlocking construction blockto account for the height of the tabs 3410, preventing any indentationsfrom the tabs 3410 from being molded into the interlocking constructionblock.

When assembled, the female mold 3500 comprises both positive spacecomprising each of the elements of the female mold 3500 and negativespace comprising open areas, allowing material to be poured into thenegative spaces of the female mold 3500 in order to manufacture aninterlocking construction block within the female mold 3500.

FIG. 36 depicts a perspective view of a male mold 3600 corresponding tothe assembled female mold 3500 of FIG. 35, in accordance with oneembodiment of the present disclosure. The male mold 3600 may comprise aflat top 3602 and a plurality of vertical pillars 3604 extendingdownwards from the underside of the flat top 3602. The pillars may endopposite the flat top 3602 with a plurality of plungers 3606. Theplurality of plungers 3606 may be sized and shaped to correspond to thenegative space of the female mold 3500. The plurality of plungers 3606may be arranged to slide around the tabs 3410 if the central core ofmold cavity defining mold component 3400 is desired in order to decreasethe overall weight of the interlocking construction block.

In FIGS. 49-51, below, the setup relationship for manufacturing aninterlocking construction block, an interlocking construction block witha top channel, and an interlocking construction block with a bottomchannel are described. In FIGS. 37A-I, the method for manufacturing aninterlocking construction block is described.

FIG. 49 depicts an exploded view of the female mold 3500 of FIG. 35 andthe male mold 3600 of FIG. 36 for manufacturing a solid interlockingconstruction block, in accordance with one embodiment of the presentdisclosure. In the embodiment, the female mold 3500 is placed upsidedown on a large, flat surface 3704, such that the male mold 3600 may bereceived within the negative space of the female mold 3500. In thisconfiguration, the male mold 3600 may push the resulting interlockingconstruction block out of the female mold 3500 from the bottom first.

FIG. 50 depicts an exploded view of the female mold 3500 of FIG. 35 andthe male mold 3600 of FIG. 36 for manufacturing an interlockingconstruction block with a top channel, as described in FIGS. 9-21, inaccordance with one embodiment of the present disclosure. In theembodiment, the female mold 3500 is placed upside down on the large,flat surface 3704, such that the male mold 3600 may be received withinthe negative space of the female mold 3500. The male mold 3600 mayadditionally comprise one or more extended plungers 5002 and 5004 thatextend below the plungers 3606. The extended plungers 5002 and 5004 maybe shaped and sized to form the top channel in the resultinginterlocking construction block by reducing the size of the negativespace of the female mold 3500. In this configuration, the male mold 3600may push the resulting interlocking construction block out of the femalemold 3500 from the bottom first.

FIG. 51 depicts an exploded view of the female mold 3500 of FIG. 35 andthe male mold 3600 of FIG. 36 for manufacturing an interlockingconstruction block with a bottom channel, as described in FIGS. 9-21, inaccordance with one embodiment of the present disclosure. In theembodiment, the female mold 3500 is placed right side up on the large,flat surface 3704, such that the male mold 3600 may be received withinthe negative space of the female mold 3500. The male mold 3600 mayadditionally comprise one or more extended plungers 5002 and 5004 thatextend below the plungers 3606. The extended plungers 5002 and 5004 maybe shaped and sized to form the bottom channel in the resultinginterlocking construction block by reducing the size of the negativespace of the female mold 3500. In this configuration, the male mold 3600may push the resulting interlocking construction block out of the femalemold 3500 from the top first.

FIGS. 37A-I depict a method 3700 for manufacturing an interlockingconstruction block with the female mold 3500 of FIG. 35 and the malemold 3600 of FIG. 36, in accordance with one embodiment of the presentdisclosure.

As shown in FIG. 37A, at step 3702, the large, flat surface 3704 may beprovided. This surface 3704 should be larger than the desired size ofthe interlocking construction block and should be made of a materialsuch that when the interlocking construction block material is pouredinto the mold, it does to bond to the surface 3704. In an embodiment,the surface 3704 is made of wood, although it could also be made ofplastics.

As shown in FIG. 37B, at step 3706, the assembled female mold 3500 ofFIG. 35 is placed on top of the large, flat surface 3704. The femalemold 3500 may be positioned with the tabs 3400 of the central core ofmold cavity defining mold component 3400 up. As described in FIGS. 49and 50, if a block without channels or a block with top channels isdesired, the female mold 3500 may be positioned upside down such thatthe top of the block will form proximate to the flat surface 3704, whileif a block with bottom channels is desired, the female mold 3500 may bepositioned right side up such that the bottom of the block with formproximate to the flat surface 3704.

In an embodiment, the internal mesh cage 4700 of FIG. 47 may be insertedinto the center cavity of the female mold 3500 to reinforce theinterlocking block during the mold process. The internal mesh cage 4700may be shaped and placed proximate to the outer perimeter of theinterlocking block and may be made from steel mesh, carbon fiber, or anyother material suitable for providing reinforcement to the interlockingblock.

As shown in FIG. 37C, at step 3708, the interlocking construction blockraw material 3710 may be poured into the central cavity of the femalemold 3500. The raw material 3710 may be a fluid cement, mortar, sand,water, or plastic mixture that hardens over time. This characteristicallows the raw material 3710 to be poured into and formed in the femalemold 3500.

As shown in FIG. 37D, at step 3712, the raw material 3710 has settledinto the female mold 3500 on top of the surface 3704. As shown here, theoverall height of the female mold 3500 is greater than the height of thepoured raw material 3710 so that the raw material 3710 is below thetabs. This also allows space for the plungers of the male mold 3600 tomate within the negative space of the female mold 3500.

As shown in FIG. 37E, at step 3714, the male mold 3600 is placed overthe female mold 3500 and the plungers 3606 are inserted into thenegative space of the female mold 3500. By this time, the raw material3710 may have been allowed to set for a predetermined amount of time,beginning the transformation from fluid cement to solid concrete. Oncethe raw material 3710 has hardened enough to maintain the form of theinterlocking construction block, the molds may be removed from theblock. As described in FIGS. 50 and 51, if a block with channels isdesired, the male mold 3600 may comprise extended plungers 5002, 5004,5102, and/or 5104 that reduce the size of the negative space of thefemale mold 3500.

As shown in FIG. 37F, at step 3716, the female mold 3500 is movedupwards towards the male mold 3600. During this step, the female mold3500 is moved around the plungers of the male mold 3600 while theinterlocking construction block 3710 remains on the flat surface 3704.

As shown in FIG. 37G, at step 3718, the female mold 3500 is movedfurther upwards around the male mold 3600.

As shown in FIG. 37H, at step 3720, the female mold 3500 has been movedfully upwards around the male mold 3600 and the molds 3500 and 3600 havebeen removed from the interlocking construction block 3710, which isshaped and sized according to the female mold 3500.

As shown in FIG. 37I, at step 3722, the finished interlockingconstruction block 3701 is removed from the flat surface 3704.

The assembled female molds described in relation to FIGS. 38-42 belowcorrespond with the interlocking construction blocks described above andare all modular so that they can be made with a standard mold setcomprising one or more molds 2900, one or more molds 3100, and two ormore connecting side wall panels. These molds may be assembled using aplurality of bolts threaded through the corresponding apertures in theconnecting side walls and molds to make an assembled mold that is thesize and shape of a desired interlocking construction block. Whilevarious shapes of assembled molds are discussed below, it is understoodthat these are not the only shapes of molds that can be made with a moldset. Further, while the central core of mold cavity defining moldcomponents 3400 are not shown in FIGS. 38-42, central core of moldcavity defining mold components 3400 may be inserted into the centercavity of any of the female molds discussed below, thereby reducing thenegative space in the female mold which reduces overall weight andmaterial needed to manufacture the interlocking construction blockswithin the female molds.

FIG. 38 depicts a top view of an assembled female mold 3800 for aninterlocking T-section construction block, which is used to connectthree walls, in accordance with one embodiment of the presentdisclosure. The assembled female mold 3800 may be used to construct theT-section constructions blocks of FIGS. 1 and 23.

The assembled female mold 3800 may comprise three two-part molds 3300,each combining the first interlocking mold component 2900 (“1”) and thesecond interlocking mold component 3100 (“2”), and a plurality ofconnecting side walls. These molds 3300 may be spaced apart from eachother in a T-configuration, with two molds 3300 a and 3300 b positionedopposite each other with the interlocking sections facing each other andconnected by a long connecting side wall 3802 on one side. The thirdmold 3300 c may be positioned between the first two molds and oriented90 degrees from the first two molds with the interlocking section facinginwards. The third mold 3300 c may be connected to the two molds 3300 aand 3300 b opposite the long connecting side wall 3802 with a pluralityof short connecting side walls 3804, 3806, 3808, and 3810.

FIG. 39 depicts a top view of an assembled female mold 3900 for aninterlocking cross-section construction block, which is used to connectfour walls, in accordance with one embodiment of the present disclosure.The assembled female mold 3900 may be used to construct thecross-section constructions blocks of FIGS. 2 and 24.

The assembled female mold 3900 may comprise four two-part molds 3300,each combining the first interlocking mold component 2900 (“1”) and thesecond interlocking mold component 3100 (“2”), and a plurality ofconnecting side walls. These molds 3300 may be spaced apart from eachother in a square configuration, with each mold 3300 a, 3300 b, 3300 c,and 3300 d oriented 90 degrees from each other and with the interlockingsections facing inwards. The molds 3300 may each be connected to eachother with a plurality of short connecting side walls 3902, 3904, 3906,3908, 3910, 3912, 3914, and 3916.

FIG. 40 depicts a top view of an assembled female mold 4000 for aninterlocking corner-section construction block, which is used to connecttwo walls at a corner, in accordance with one embodiment of the presentdisclosure. The assembled female mold 4000 may be used to construct thecorner-section constructions blocks of FIGS. 3 and 25.

The assembled female mold 4000 may comprise two two-part molds 3300,each combining the first interlocking mold component 2900 (“1”) and thesecond interlocking mold component 3100 (“2”), and a plurality ofconnecting side walls. These molds 3300 may be spaced apart from eachother in a corner-configuration, with the molds 3300 a and 3300 boriented 90 degrees from each other and with the interlocking sectionsfacing inwards. The molds 3300 may each be connected to each other withtwo medium connecting side walls 4002 and 4004 forming the outside ofthe corner and two short connecting side walls 4006 and 4008 forming theinside of the corner.

FIG. 41 depicts a top view of an assembled female mold 4100 for aninterlocking end-piece construction block, in accordance with oneembodiment of the present disclosure. The assembled female mold 4100 maybe used to construct the end-piece constructions blocks of FIGS. 4 and26.

The assembled female mold 4100 may comprise one two-part molds 3300,each combining the first interlocking mold component 2900 (“1”) and thesecond interlocking mold component 3100 (“2”), and a plurality ofconnecting side walls. The mold 3300 may be positioned with theinterlocking section facing inwards with two long connecting side walls4102 and 4106 extending away from the interlocking section and connectedby a medium connecting sidewall 4104 that is opposite the mold 3300 andthe width of the mold 3300.

FIG. 42 depicts a top view of an assembled female mold 4200 for of aninterlocking stretcher construction block, in accordance with oneembodiment of the present disclosure. The assembled female mold 4200 maybe used to construct the stretcher constructions blocks of FIGS. 5 and27.

The assembled female mold 4200 may comprise two two-part molds 3300,each combining the first interlocking mold component 2900 (“1”) and thesecond interlocking mold component 3100 (“2”), and a plurality ofconnecting side walls. These molds 3300 may be spaced apart from eachother and with the interlocking sections facing inwards. The molds 3300a and 3300 b may each be connected to each other with two longconnecting sidewalls 4202 and 4204.

In each of the assembled female molds depicted in FIGS. 38-42, the moldsmay be full height or half-height, allowing the resulting manufacturedconstruction blocks to be alternated in an interlocking pattern betweenthe seams of the blocks in the wall, creating a “woven” effect whichlocks the blocks in place in three axes and allows even distribution ofstructural weights and stresses, even during seismic or wind events.

FIG. 43 depicts a perspective view and FIG. 44 depicts a top view of athird interlocking mold component 4300, in accordance with oneembodiment of the present disclosure. The third interlocking moldcomponent 4300, or “3” in some views, when combined with twointerlocking mold components 2900, or “1” in some views, to create arepeating pattern that can be used to manufacture more than oneinterlocking construction block at a time.

As seen in FIG. 43, the third interlocking mold component 4300 may be agenerally vertical mold and may comprise two geometric protrusions 4302and 4304 connected by a central shoulder section 4306. Like thegeometric protrusion 3104 of the second interlocking mold component3100, the geometric protrusions 4302 and 4304 may be sized and shaped toform a gap between the first and second interlocking portions of aninterlocking block that is created with the mold set. When combined withthe two first interlocking mold components 2900, two geometric recessmay be sized and shaped to form a first interlocking portion catch of aninterlocking block that is created with the mold set.

Both geometric protrusions 4302 and 4304 may comprise a plurality ofapertures 4308 that may extend within, but not through, the geometricprotrusions 4302 and 4304. These apertures 4308 may be used to connectthe first interlocking mold components 2900 to the third interlockingmold component 4300.

In an embodiment, the third mold component 4300 may have outerdimensions of approximately 100 mm by 70 mm, and more specifically, mayhave outer dimensions of approximately 97.5 mm by 72.5 mm. In anembodiment, the mold 4300 may weigh between 5 and 8 kilograms, and morespecifically, may weigh approximately 6.37 kilograms.

FIG. 45 depicts a perspective view of two first interlocking moldcomponents 2900 of FIG. 29 connected to the third interlocking moldcomponent 4300 of FIG. 43 to create a three-part interlocking sectionmold 4500, in accordance with one embodiment of the present disclosure.

When the apertures 2912 of the first interlocking mold components 2900and the apertures 4308 of the third interlocking mold component 4300 arealigned, threaded bolts (not shown) may be inserted through washers (notshown) and threaded into the apertures 2912 of the first interlockingmold components 2900 and then threaded into the apertures 4308 of thethird interlocking mold component 4300. Once connected, the three-partmold 4500 may be used to create a repeating interlocking section of aninterlocking construction block. This three-part mold 4500 using twomolds 1 and one mold 3 may be used to create two interlocking sectionsfor molds for any shape and size of interlocking construction block byusing a combination of two-part molds, connecting side walls, andconnecting end walls.

FIG. 46 depicts a top view of an assembled repeating female mold 4600for a plurality of interlocking stretcher construction blocks, inaccordance with one embodiment of the present disclosure. A plurality oftwo-part molds 3300 can be combined with a plurality of three-part molds4500 and extended connecting side walls 4602 and 4604 to create therepeating female mold 4600 in order to manufacture four stretcherinterlocking construction blocks at a time. Any number “x” ofinterlocking construction blocks may be manufactured in a line byplacing two two-part molds 3300 at the ends and separating them with(x−1) three-part molds 4500. In addition, and as shown in FIG. 46, rowsof repeating female molds 4600 may be connected end to end withconnecting end walls to create a repeating female mold with more thanone row of interlocking construction blocks. By utilizing the three-partmolds 4500, more than one interlocking construction block can be pouredat a time, reducing the time required to manufacture each block.

These repeating female molds 4600 may be assembled using a plurality ofbolts threaded through the corresponding apertures in the connectingside walls and molds in order to make an assembled mold that results inthe desired number of interlocking construction blocks. Further, whilecentral core of mold cavity defining mold components 3400 are not shownin FIG. 46, central core of mold cavity defining mold components 3400may be inserted into the center cavity of any of the female molds,thereby reducing the overall weight and material needed to manufacturethe interlocking construction blocks.

The modular molds described in FIGS. 29-46 may be manufactured fromsteel or stainless steel, depending on the environment that the moldswill be used in. These molds will be able to withstand high pressuresand temperatures in order to allow concrete blocks to be formed withinthe molds.

Additional Interlocking Construction Blocks and Related Mold SetEmbodiments

The interlocking construction blocks and related mold sets of FIGS.52-79, described below, may be similar to the interlocking constructionblocks and mold sets described in FIGS. 1-46, but may additionallyinclude internal mesh cages for reinforcement, as described in FIGS.47-48. Therefore, the disclosure of FIGS. 1-46 is herein incorporated byreference in relation to FIGS. 52-79.

FIG. 52 depicts a top view and FIG. 53 depicts a perspective view of aninterlocking T-section construction block 5200 with an internal meshcage 5202, in accordance with one embodiment of the present disclosure.FIG. 54 depicts a top view and FIG. 55 depicts a perspective view of anassembled repeating female mold 5400 for manufacturing a plurality ofthe interlocking T-section construction blocks 5200 of FIG. 52, which isused to connect three walls, in accordance with one embodiment of thepresent disclosure. As shown in FIGS. 54-55, the disclosed female mold5400 comprises 25 cavities for manufacturing 25 construction blocks5200, although any number of cavities may be provided in the female mold5400 for making a desired number of T-section construction blocks 5200.

FIG. 56 depicts a top view and FIG. 57 depicts a perspective view of aninterlocking cross-section construction block 5600 with an internal meshcage 5602, which is used to connect four walls, in accordance with oneembodiment of the present disclosure. FIG. 58 depicts a top view andFIG. 59 depicts a perspective view of an assembled repeating female mold5800 for manufacturing a plurality of the interlocking cross-sectionconstruction blocks 5600 of FIG. 56, which is used to connect fourwalls, in accordance with one embodiment of the present disclosure. Asshown in FIGS. 58-59, the disclosed female mold 5800 comprises 20cavities for manufacturing 20 construction blocks 5600, although anynumber of cavities may be provided in the female mold 5800 for making adesired number of cross-section construction blocks 5600.

FIG. 60 depicts a top view and FIG. 61 depicts a perspective view of aninterlocking corner-section construction block 6000 with an internalmesh cage 6002, in accordance with one embodiment of the presentdisclosure. FIG. 62 depicts a top view and FIG. 63 depicts a perspectiveview of an assembled repeating female mold 6200 for manufacturing aplurality of the interlocking corner-section construction blocks 6000 ofFIG. 60, in accordance with one embodiment of the present disclosure. Asshown in FIGS. 62-63, the disclosed female mold 6000 comprises 30cavities for manufacturing 30 construction blocks 6000, although anynumber of cavities may be provided in the female mold 6200 for making adesired number of corner-section construction blocks 6000.

FIG. 64 depicts a top view and FIG. 65 depicts a perspective view of aninterlocking end-section construction block 6400 with an internal meshcage 6402, in accordance with one embodiment of the present disclosure.FIG. 66 depicts a top view and FIG. 67 depicts a perspective view of anassembled repeating female mold 6600 for manufacturing a plurality ofthe interlocking end-section construction blocks 6400 of FIG. 64, inaccordance with one embodiment of the present disclosure. As shown inFIGS. 66-67, the disclosed female mold 6600 comprises 42 cavities formanufacturing 42 construction blocks 6400, although any number ofcavities may be provided in the female mold 6600 for making a desirednumber of end-section construction blocks 6400.

FIG. 68 depicts a top view and FIG. 69 depicts a perspective view of aninterlocking stretcher construction block 6800 with an internal meshcage 6802, in accordance with one embodiment of the present disclosure.FIG. 70 depicts a top view and FIG. 71 depicts a perspective view of anassembled repeating female mold 7000 for manufacturing a plurality ofthe interlocking stretcher construction blocks 6800 of FIG. 68, inaccordance with one embodiment of the present disclosure. As shown inFIGS. 70-71, the disclosed female mold 7000 comprises 28 cavities formanufacturing 28 construction blocks 6800, although any number ofcavities may be provided in the female mold 7000 for making a desirednumber of stretcher construction blocks 6800. In the embodimentsdepicted in FIGS. 68-71, the resulting stretcher construction blocks6800 may be standard 12″ long and 8″ tall stretcher blocks.

FIG. 72 depicts a top view and FIG. 73 depicts a perspective view of aninterlocking half-stretcher construction block 7200 with an internalmesh cage 7202, in accordance with one embodiment of the presentdisclosure. FIG. 74 depicts a top view and FIG. 75 depicts a perspectiveview of an assembled repeating female mold 7000 for manufacturing aplurality of the interlocking half-stretcher construction blocks 7200 ofFIG. 72, in accordance with one embodiment of the present disclosure. Asshown in FIGS. 74-75, the disclosed female mold 7400 comprises 28cavities for manufacturing 28 construction blocks 7200, although anynumber of cavities may be provided in the female mold 7400 for making adesired number of half-stretcher construction blocks 7200. In theembodiments depicted in FIGS. 72-75, the resulting half-stretcherconstruction blocks 7200 may be standard 12″ long and 4″ tallhalf-stretcher blocks.

FIG. 76 depicts a top view and FIG. 77 depicts a perspective view of aninterlocking 9″ spacer construction block 7600 with an internal meshcage 7602, in accordance with one embodiment of the present disclosure.FIG. 78 depicts a top view and FIG. 79 depicts a perspective view of anassembled repeating female mold 7800 for manufacturing a plurality ofthe interlocking 9″ stretcher construction blocks 7600 of FIG. 68, inaccordance with one embodiment of the present disclosure. As shown inFIGS. 78-79, the disclosed female mold 7800 comprises 28 cavities formanufacturing 28 construction blocks 7600, although any number ofcavities may be provided in the female mold 7800 for making a desirednumber of 9″ spacer construction blocks 7600. In the embodimentsdepicted in FIGS. 76-79, the resulting stretcher construction blocks7600 may be 9″ long and 8″ tall stretcher blocks, although other lengthsof stretcher blocks 7600 to create desired lengths of wall structures.

As depicted in FIGS. 52-79, one or more repeating mold components may bereceived within the central cavity, thereby creating repeating geometricopenings and reducing the volume of the central cavities within thefemale mold. In an embodiment, the one or more repeating mold componentsmay be the geometric third interlocking mold components depicted in FIG.43, which are used to create repeating patterns within the centralcavity. In an embodiment, the one or more repeating mold components maybe square or rectangular repeating mold components, which are used toreduce the overall volume of the central cavity within the female mold.By reducing the overall volume of the central cavity, the amount of rawmaterial received within the central cavity and needed to create theconstruction blocks is also reduced.

It is to be understood that in order to interlock and self-alignproperly, different blocks within a family of an interlockingconstruction block system will utilize the same geometries ofinterlocking portions. That is, the interlocking construction blocks ofFIGS. 1-6 may interlock and self-align with each other without the useof a binding agent such as mortar during assembly, the interlockingconstruction blocks of FIGS. 23-28 may interlock and self-align witheach other without the use of a binding agent such as mortar duringassembly, and the interlocking construction blocks of FIGS. 52-79 mayinterlock and self-align with each other without the use of a bindingagent such as mortar during assembly. But blocks with differentinterlocking section geometries may not interlock and self-align witheach other without the use of a binding agent such as mortar duringassembly.

In each of the embodiments described in relation to FIGS. 1-28 and FIGS.52-79, the interlocking constructions blocks are operable to interlockwith each other in at least three directions. The blocks may interlockalong three axes: a left/right axis, a front/back axis, and an up/downaxis. Each of the various configurations of blocks can be manufacturedin different widths to conform to building code requirements around theworld.

While various embodiments in accordance with the principles disclosedherein have been described above, it should be understood that they havebeen presented by way of example only, and are not limiting. Thus, thebreadth and scope of the invention(s) should not be limited by any ofthe above-described exemplary embodiments, but should be defined only inaccordance with the claims and their equivalents issuing from thisdisclosure. Furthermore, the above advantages and features are providedin described embodiments, but shall not limit the application of suchissued claims to processes and structures accomplishing any or all ofthe above advantages.

It will be understood that the principal features of this disclosure canbe employed in various embodiments without departing from the scope ofthe disclosure. Those skilled in the art will recognize, or be able toascertain using no more than routine experimentation, numerousequivalents to the specific procedures described herein. Suchequivalents are considered to be within the scope of this disclosure andare covered by the claims.

Additionally, the section headings herein are provided for consistencywith the suggestions under 37 CFR 1.77 or otherwise to provideorganizational cues. These headings shall not limit or characterize theinvention(s) set out in any claims that may issue from this disclosure.Specifically, and by way of example, although the headings refer to a“Field of Invention,” such claims should not be limited by the languageunder this heading to describe the so-called technical field. Further, adescription of technology in the “Background of the Invention” sectionis not to be construed as an admission that technology is prior art toany invention(s) in this disclosure. Neither is the “Summary” to beconsidered a characterization of the invention(s) set forth in issuedclaims. Furthermore, any reference in this disclosure to “invention” inthe singular should not be used to argue that there is only a singlepoint of novelty in this disclosure. Multiple inventions may be setforth according to the limitations of the multiple claims issuing fromthis disclosure, and such claims accordingly define the invention(s),and their equivalents, that are protected thereby. In all instances, thescope of such claims shall be considered on their own merits in light ofthis disclosure, but should not be constrained by the headings set forthherein.

The use of the word “a” or “an” when used in conjunction with the term“comprising” in the claims and/or the specification may mean “one,” butit is also consistent with the meaning of “one or more,” “at least one,”and “one or more than one.” The use of the term “or” in the claims isused to mean “and/or” unless explicitly indicated to refer toalternatives only or the alternatives are mutually exclusive, althoughthe disclosure supports a definition that refers to only alternativesand “and/or.” Throughout this application, the term “about” is used toindicate that a value includes the inherent variation of error for thedevice, the method being employed to determine the value, or thevariation that exists among the study subjects.

As used in this specification and claim(s), the words “comprising” (andany form of comprising, such as “comprise” and “comprises”), “having”(and any form of having, such as “have” and “has”), “including” (and anyform of including, such as “includes” and “include”) or “containing”(and any form of containing, such as “contains” and “contain”) areinclusive or open-ended and do not exclude additional, unrecitedelements or method steps.

As used herein, words of approximation such as, without limitation,“about”, “substantial” or “substantially” refers to a condition thatwhen so modified is understood to not necessarily be absolute or perfectbut would be considered close enough to those of ordinary skill in theart to warrant designating the condition as being present. The extent towhich the description may vary will depend on how great a change can beinstituted and still have one of ordinary skilled in the art recognizethe modified feature as still having the required characteristics andcapabilities of the unmodified feature. In general, but subject to thepreceding discussion, a numerical value herein that is modified by aword of approximation such as “about” may vary from the stated value byat least ±1, 2, 3, 4, 5, 6, 7, 10, 12 or 15%.

The term “or combinations thereof” as used herein refers to allpermutations and combinations of the listed items preceding the term.For example, “A, B, C, or combinations thereof is intended to include atleast one of: A, B, C, AB, AC, BC, or ABC, and if order is important ina particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB.Continuing with this example, expressly included are combinations thatcontain repeats of one or more item or term, such as BB, AAA, AB, BBC,AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan willunderstand that typically there is no limit on the number of items orterms in any combination, unless otherwise apparent from the context.

All of the compositions and/or methods disclosed and claimed herein canbe made and executed without undue experimentation in light of thepresent disclosure. While the compositions and methods of thisdisclosure have been described in terms of preferred embodiments, itwill be apparent to those of skill in the art that variations may beapplied to the compositions and/or methods and in the steps or in thesequence of steps of the method described herein without departing fromthe concept, spirit and scope of the disclosure. All such similarsubstitutes and modifications apparent to those skilled in the art aredeemed to be within the spirit, scope and concept of the disclosure asdefined by the appended claims.

What is claimed is:
 1. An interlocking construction block, comprising:(a) a core section comprising: one or more wall sides; and first andsecond interlocking section attachment sides; and (b) a firstinterlocking section comprising: (i) a first interlocking portion, whichis defined by: a first interlocking portion attachment end, a firstinterlocking portion catch end, and a first interlocking portion catch;(ii) a second interlocking portion, which is defined by: a secondinterlocking portion attachment end, and a second interlocking portionkey; (c) a second interlocking section comprising: (i) a thirdinterlocking portion, which is defined by: a third interlocking portionattachment end, a third interlocking portion catch end, and a thirdinterlocking portion catch; (ii) a fourth interlocking portion, which isdefined by: a fourth interlocking portion attachment end, and a fourthinterlocking portion key; and (d) a first interlocking section bridgeoperable to connect the first interlocking section (b) to the firstinterlocking section attachment side of the core section, and a secondinterlocking section bridge operable to connect the second interlockingsection (c) to the second interlocking section attachment side of thecore section, wherein the second interlocking section attachment side isspaced approximately 90 degrees from the first interlocking sectionattachment side.
 2. The interlocking construction block of claim 1,wherein the one or more wall sides of the core section further comprisea first wall side end and a second wall side end.
 3. The interlockingconstruction block of claim 2, wherein the first interlocking sectionattachment side further comprises a first interlocking sectionattachment side end and the second interlocking section attachment sidefurther comprises a second interlocking section attachment side end. 4.The interlocking construction block of claim 3, wherein each of thefirst and second interlocking sections further comprise one or morenegative space gaps operable to receive an interlocking section of asecond interlocking construction block.
 5. The interlocking constructionblock of claim 1, wherein the first and second interlocking sections arespaced approximately 90 degrees from each other about the core sectionsuch that the block is operable to connect two wall structures at acorner.
 6. The interlocking construction block of claim 5, wherein theblock is a corner block.
 7. The interlocking construction block of claim1, further comprising an internal channel intersecting the core sectionabout a horizontal longitudinal axis, the internal channel configured toreceive a reinforcing member or operable as an internal conduit.
 8. Theinterlocking construction block of claim 7, wherein the reinforcingmember is constructed from steel.
 9. The interlocking construction blockof claim 1, wherein the block is constructed from a cement mixture,aggregate, sand, water, or other raw materials hardened into concrete.10. An interlocking construction block, comprising: (a) a core sectionhaving two interlocking section attachment sides; and (b) twointerlocking sections, each interlocking section comprising: (i) a firstinterlocking portion, which is defined by: a first interlocking portionattachment end; a first interlocking portion catch end; and a firstinterlocking portion catch; (ii) a second interlocking portion, which isdefined by: a second interlocking portion attachment end; and a secondinterlocking portion key; and (c) two interlocking section bridges,wherein: (i) a first interlocking section bridge is configured toconnect the first interlocking section to the first interlocking sectionattachment side of the core section; (ii) a second interlocking sectionbridge is configured to connect the second interlocking section to thesecond interlocking section attachment side of the core section, whereinthe second interlocking section attachment side is spaced approximately90 degrees from the first interlocking section attachment side.
 11. Theinterlocking construction block of claim 10, further comprising internalchannels intersecting the core section about a horizontal longitudinalaxis and a horizontal lateral axis, wherein each of the internalchannels is configured to receive a reinforcing member or operable as aninternal conduit.
 12. The interlocking construction block of claim 10,wherein each of the first and second interlocking sections furthercomprises one or more negative space gaps operable to receive aninterlocking section of a second interlocking construction block. 13.The interlocking construction block of claim 10, wherein the firstinterlocking section and the second interlocking section are spacedapproximately 90 degrees from each other about the core section, suchthat the block is operable to create a corner-section constructionblock.
 14. The interlocking construction block of claim 10, wherein theblock is operable to connect two wall structures, wherein each of thetwo wall structures is spaced approximately 90 degrees from one another.15. An interlocking construction block system, comprising: (a) first andsecond wall structures; and (b) an interlocking construction block,comprising: (i) a core section having first and second interlockingsection attachment sides; and (ii) a first interlocking sectioncomprising: a first interlocking portion, which is defined by a firstinterlocking portion attachment end, a first interlocking portion catchend, and a first interlocking portion catch; and a second interlockingportion which is defined by a second interlocking portion attachmentend, and a second interlocking portion key; (iii) a second interlockingsection comprising: a third interlocking portion, which is defined by athird interlocking portion attachment end, a third interlocking portioncatch end, and a third interlocking portion catch; and a fourthinterlocking portion, which is defined by a fourth interlocking portionattachment end, and a fourth interlocking portion key; and (iv) a firstinterlocking section bridge operable to connect the first interlockingsection to the first interlocking section attachment side of the coresection, and a second interlocking section bridge operable to connectthe second interlocking section to the second interlocking sectionattachment side of the core section, wherein the second interlockingsection attachment side is spaced approximately 90 degrees from thefirst interlocking section attachment side, and wherein the first andsecond interlocking sections are spaced approximately 90 degrees fromeach other about the core section such that the interlockingconstruction block is operable to connect the first wall structure andthe second wall structure about a corner.
 16. The interlockingconstruction block system of claim 15, wherein the first interlockingsection attachment side further comprises a first interlocking sectionattachment side end and the second interlocking section attachment sidefurther comprises a second interlocking section attachment side end. 17.The interlocking construction block system of claim 16, wherein each ofthe first and second interlocking sections further comprise one or morenegative space gaps.
 18. The interlocking construction block system ofclaim 17, further comprising an internal channel intersecting the coresection about a horizontal longitudinal axis, the internal channelconfigured to receive a reinforcing member or operable as an internalconduit.
 19. The interlocking construction block system of claim 18,wherein the reinforcing member is constructed from steel.
 20. Theinterlocking construction block system of claim 19, wherein theinterlocking construction block is constructed from a cement mixture,aggregate, sand, water, or other raw materials hardened into concrete.